Professional Documents
Culture Documents
By S K Mondal
Shell Moulding
The sand is mixed with a thermosetting resin is allowed to come in contact with a heated metal pattern (2000C).
A skin (shell) of about 3.5 mm of sand and plastic mixture adhere to the pattern. Then the shell is removed from the pattern. The cope and drag shells are kept in a flask with necessary backup material and the molten metal is poured into the mold.
Can produce complex parts. A good surface finish and good size tolerance
to loading the sand. In the course of sand mixing, the soluble phenol formaldehyde resin is added. The mixer is allowed to cool up to 80 90o C. Hot coting gives better
Advantages
Dimensional accuracy.
Limitations
Expensive pattern
Applications
Cylinders and cylinder heads for air- cooled IC
engines
Automobile transmission parts. Piston rings
IES-2005
In shell moulding, how can the shell thickness be accurately maintained? (a) By controlling the time during which the pattern is in contact with mould (b) By controlling the time during which the pattern is heated (c) By maintaining the temperature of the pattern in the range of 175oC 380oC (d) By the type of binder used
IAS-2007
The mould in shell moulding process is made up of which of the following? (a) Gypsum + setting agents (b) Green sand + clay (c) Sodium silicate + dried sand (d) Dried silica + phenolic resin
Investment Casting
Investment casting process or lost wax process Basic steps: 1. Produce expendable wax, plastic, or polystyrene patterns. 2. Assemble these patterns onto a gating system 3. Investing or covering the pattern assembly with refractory slurry 4. Melting the pattern assembly to remove the pattern material 5. Firing the mould to remove the last traces of the pattern material 6. Pouring molten metal 7. Knockout, cutoff and finishing.
built around a tree assembly by repeatedly dipping a pattern into a slurry (refractory material such as zircon with binder).
After each dipping and stuccoing is completed, the
IES 2009
2 marks
Advantages
Tight dimensional tolerances Excellent surface finish (1.2 to 3.0 m ) Machining
can
be
reduced
or
completely
eliminated
High melting point alloy can be cast, almost any
Limitations
Costly patterns and moulds
Labour costs can be high
Limited size
Applications
Aerospace and rocket components.
Vanes and blades for gas turbines.
Surgical instruments
IES 2011
The proper sequence of investment casting steps is : (a) Slurry coating pattern melt out-Shakeout Stucco coating (b) Stucco coating Slurry coating Shakeout Pattern melt out (c) Slurry coating Stucco coating Pattern melt out Shakeout (d) Stucco coating Shakeout Slurry coating Pattern melt out
IAS-1996
Light and intricate parts with close dimensional tolerances of the order of 0.005 mm are produced by (a) Investment casting (b) Die casting (c) Centrifugal casting (d) Shell mould casting
Advantages
Good surface finish and dimensional accuracy
Metal mold gives rapid cooling and fine-grain structure
Multiple-use molds.
Disadvantages
High initial mold cost Shape, size, and complexity are limited Mold life is very limited with high-melting-point
metals such as steel. Low melting point metals can be cast Aluminum Zinc Magnesium alloys Brass Cast iron
Applications
Pistons/cylinders/rods
Gears
Kitchenware
Die Casting
Molten metal is injected into closed metal dies under
Video
contamination Metal starts in a heated cylinder A piston forces metal into the die The piston retracts, and draws metal in Metal: Lead, Tin, Zinc
Hot Chamber
cools
Copper, Brass and Aluminium can cast.
Advantages
Extremely smooth surfaces (1 m)
casting
Intricate parts possible Minimum finishing operations Thin sections possible
Limitations
High initial die cost
Limited to high-fluidity nonferrous metals Part size is limited Porosity may be a problem Some scrap in sprues, runners, and flash, but this can
be directly recycled
Applications
Carburettors Automotive parts Bathroom fixtures
Toys
Common metals
Alloys of aluminum, zinc, magnesium, and lead
Also possible with alloys of copper and tin
IES 2011
Consider the following advantages of die casting over sand casting : 1. Rapidity of the process 2. Smooth surface 3. Strong dense metal structure Which of these advantages are correct ? (a) 1, 2 and 3 (b) 1 and 2 only (c) 2 and 3 only (d) 1 and 3 only
IAS-2007
Consider the following statements: 1. Zinc die castings have low strength. 2. In the die casting process, very thin sections or complex shapes can be obtained easily. Which of the statements given above is/are correct? (a) 1 only (b) 2 only (c) Both 1 and 2 (d) Neither 1 nor 2
IES 2011
Consider the following statements : 1. Hot chamber machine is used for casting zinc, tin and other low melting alloys. 2. Cold chamber machine is used for die casting of ferrous alloys 3. Rapid cooling rate in die casting produces high strength and quality in many alloys. Which of these statements are correct? (a) 1, 2 and 3 (b) 1 and 2 only (c) 2 and 3 only (d) 1 and 3 only
Centrifugal Casting
Process: Molten metal is introduced into a rotating sand,
metal, or graphite mould, and held against the mould wall by centrifugal force until it is solidified
A mold is set up and rotated along a vertical (rpm is
Properties
The mechanical properties of centrifugally cast jobs are
better compared to other processes, because the inclusions such as slag and oxides get segregated towards the centre and can be easily removed by machining. Also, the pressure acting on the metal throughout the solidification causes the porosity to be eliminated giving rise to dense metal. No cores are required for making concentric holes in the case of true centrifugal casting.
Advantages
Fine grained structure at the outer surface of the
casting free of gas and shrinkage cavities and porosity Formation of hollow interiors in cylinders without cores Can produce a wide range of cylindrical parts, including ones of large size. Good dimensional accuracy, soundness, and cleanliness There is no need for gates and runners, which increases the casting yield, reaching almost 100 %.
Limitations
More segregation of alloy component during pouring under
metallic inclusions
Inaccurate internal diameter Shape is limited. Spinning equipment can be expensive Poor machinability
Common metals
IES-2009
Which of the following are the most likely characteristics in centrifugal casting? (a) Fine grain size and high porosity (b) Coarse grain size and high porosity (c) Fine grain size and high density (d) Coarse grain size and high density
Semi-centrifugal Casting
Centrifugal force assists the flow of metal from a
central reservoir to the extremities of a rotating symmetrical mold, which may be either expendable or
multiple-use
Rotational speeds are lower than for true centrifugal
casting
Cores can be used to increase the complexity of the
product.
Centrifuging
Uses centrifuging action to force the metal from a central
pouring reservoir into separate mold cavities that are offset from the axis of rotation.
Low speed
May used to assist in the pouring of investment casting
trees.
Slush Casting
Slush casting is a variation of the permanent mold process
in which the metal is permitted to remain in the mold only until a shell of the desired thickness has formed. The mold is then inverted and the remaining liquid is poured out. When the mold halves are separated, the resulting casting is a hollow shape with good surface detail but variable wall thickness. Frequently used to cast low-melting-temperature metals into ornamental objects such as candlesticks, lamp bases, and statuary.
IES 2011
The method of casting for producing ornamental pieces are: (a) Slush and gravity casting (b) Pressed and slush casting (c) Gravity and semi permanent mould casting (d) Semi permanent mould and pressed casting
IES - 2012
The process of making hollow castings of non-circular shape and desired thickness by permanent mould without the use of cores is known as (a) Die casting (b) Slush casting (c) Pressed casting (d) Centrifugal casting
Squeeze Casting
Process: 1. Molten metal is poured into an open face die. 2. A punch is advanced into the die, and to the metal. 3. Pressure (less than forging) is applied to the punch and die while the part solidifies. 4.The punch is retracted, and the part is knocked out with an ejector pin. Overcomes problems with feeding the die, and produces near net, highly detailed parts.
IES 2009
2 marks
Plaster Casting
Process: A slurry of plaster, water, and various additives is
additives is pouted over a pattern and allowed to set. The pattern is removed and the mould is baked to remove excess water. After pouring and solidification, the mould is broken and the casting is removed. Advantage: High dimensional accuracy and smooth surface finish, thin sections and intricate detail can produce. Limitations: Lower-temperature nonferrous metals only: Common metals: Primarily aluminium and copper
Pit Moulding
This method is used for very large castings and is done on
IES-1996
Which of the following pairs are correctly matched? 1. Pit moulding ..................For large jobs. 2. Investment moulding ... Lost wax process. 3. Plaster moulding Mould prepared in gypsum. (a) 1, 2 and 3 (b) 1 and 2 (c) 1 and 3 (d) 2 and 3
Loam Moulding
Moulding loam is generally artificially composed of
IES-1997
Which one of the following pairs is not correctly matched? (a) Aluminium alloy piston Pressure die casting (b) Jewellery.. Lost wax process (c) Large pipes ..Centrifugal casting (d) Large bells Loam moulding
GATE-1998
List I (A) Sand casting circular shapes only (B) Plaster mould casting skins and soft interior (C) Shell mould casting casting processing (D) Investment casting List II (1) Symmetrical and (2) Parts have hardened
(3)
(4)
Minimum postParts have a tendency to warp Parts have soft skin and hard interior Suitable only for nonferrous metals
(5)
(6)
Option
A
Q. No
13
Option
C
2
3
A
C
14
15
D
D
4
5
A
D
16
17
B
B
6
7
A
D
18
19
B
D
8
9
C
B
20
21
A
A
10
11 12
D
A B
1
2
D
C
11
12
A
A
3
4 5 6 7 8 9 10
C
B C A D C B D
13
14
D
A
15
16
A
B
17